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Applications of Wire Harnesses12/3/2023 Wire harnesses come in various types designed for specific applications and industries. Each category often has its own unique requirements and needs to follow certain industry standards. Here are some common applications:
1. Automotive Wire Harnesses: These are extensively used in vehicles for connecting various electronic components, lights, sensors, and more. They're tailored to withstand harsh environmental conditions, vibrations, and high temperatures. Usually a manufacturer that has a IATF 16949 certified quality management system is preferred for Automotive Tier One and Two suppliers. 2. Aerospace Wire Harnesses: Aerospace applications require highly specialized harnesses due to stringent safety and performance standards. They're designed to be lightweight, durable, and resistant to extreme temperatures and radiation. Usually a manufacturer that adheres to the AS9100 standard is ideal with additional emphasis on product safety, management of counterfeit parts, ethical behavior, and human factors for a quality management system. 3. Industrial Wire Harnesses: These are used in industrial machinery and equipment, ensuring proper connectivity between different electrical components. They're built to withstand rugged conditions and heavy usage with the right sleeving and tubing used. 4. Medical Wire Harnesses: Customized for medical devices and equipment, these harnesses prioritize precision, cleanliness, and compliance with strict regulatory standards. It is of utmost importance that a company has ISO 13485 certification which highlights non-conformance detection, continual product quality control, and excellent record keeping. 5. Data and Telecommunication Wire Harnesses: Used in networking and telecommunication systems, these harnesses manage the complex connections between data and communication devices. They prioritize high-speed data transmission, reliability, and signal integrity. 6. Energy and Renewable Energy Wire Harnesses: Harnesses used in energy sectors, including solar and wind energy systems, are designed for efficient power distribution, often in outdoor environments and varying weather conditions. These often require specialized components like medium and high voltage cables and thicker power battery cables for rugged environments. 7. Consumer Electronics Wire Harnesses: These are found in appliances, computers, entertainment systems, and more. They're designed for space efficiency and to accommodate various electronic components within a confined space. 8. Custom Wire Harnesses: These are designed to meet specific, often unique, requirements for various applications across industries, catering to specialized needs that standard harnesses might not address. Each type of wire harness is crafted to meet specific requirements in terms of durability, electrical specifications, environmental conditions, and safety standards dictated by the industry or application it serves. Here at Everlink, we are proficient with servicing customers in a wide range of industries and are committed to quality control at all levels of production; holding multiple certifications and standards. Contact us today to discuss your custom needs and project!
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Function of Oil Pressure Sensors6/6/2023 Oil pressure sensors in cars play a crucial role in monitoring the oil pressure within the engine. Their primary function is to measure the oil pressure and send this information to the vehicle's engine control unit (ECU) or gauge. In common terminology, these can also be called the oil pressure switch, oil pressure sender, or oil pressure sending unit but no matter what they are called, they serve critical safety functions.
1. Monitoring Oil Pressure: They constantly monitor the oil pressure within the engine. Low oil pressure can indicate a problem such as low oil level, oil leakage, or oil viscosity issues. 2. Engine Protection: Maintaining proper oil pressure is vital for engine lubrication. Adequate oil pressure ensures that engine components are sufficiently lubricated, reducing friction and wear. If the pressure drops too low, it could lead to engine damage due to insufficient lubrication. 3. Warning Indicator: When the oil pressure drops below a safe level, the sensor triggers a warning light on the dashboard or gauge to alert the driver. This warning signals the need for immediate attention to prevent potential engine damage. 4. Safe Operation: Monitoring oil pressure helps ensure the safe operation of the engine. It allows for timely maintenance or repairs, preventing catastrophic engine failure due to insufficient lubrication. 5. Diagnostic Tool: If there are fluctuations or irregularities in oil pressure, it can indicate underlying issues within the engine. Car mechanics can use the data from the sensor to diagnose and address potential problems before they worsen. Overall, oil pressure sensors serve as a critical safety and maintenance feature in vehicles, helping to protect the engine and ensuring optimal performance by monitoring the lubrication system's health.
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Types of Labels for Wire Harnesses2/20/2023 Labels for wire harnesses are essential for identification, organization, and maintenance. This can help alleviate troubleshooting and repair work to trace specific labels. For complex wire harnesses, using different colored cables lends itself to the same idea as it enables faster identification and improves overall cable management. Here are several types commonly used: 1. Heat-Shrink Labels: These labels shrink when heat is applied, conforming to the wire's shape for durable identification. Ideal for wire harnesses used environments exposed to vibrations and extreme temperatures as these labels are resistant to heat, water, and chemicals. 5. Cable Tags/Ties: Tags or ties that can be attached directly to cables or wires, providing a surface for labeling. Some opt to apply just the colored cable ties for fast identification. 6. Engraved Labels/Tags: Durable labels made of engraved plastic or metal for long-term identification, often used in industrial settings. 7. Barcode Labels: Labels with machine-readable barcodes for easy scanning and tracking of wires. 8. Laser Wire Marking: Laser marking can inscribe codes and numbers information directly on the wire without altering the wire properties and damaging it. This method allows for high precision in a small wire area and is highly versatile. However, laser wire marking is frequently more costly and labor intensive. Choosing the appropriate label type depends on factors like environmental conditions, durability requirements, ease of application, and the level of detail needed for identification. Especially when installing automotive wire harnesses, production workers need to be able to rapidly distinguish areas linking to different modules (Ex. front, rear, headlight, taillights, horn, engine, fuel pump, ignition, throttle, and more).
Here at Everlink, we can accommodate a variety of labeling requirements for wire harness and cable assembly production. Contact us today to discuss your custom needs and project!
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Wire Harness Component Suppliers8/8/2022 One of the biggest distinctions in varying wire harnesses comes down to the materials used for the internal connectors and components. Beyond accounting for labor costs, the raw material costs ultimately make up a significant portion of the cost factor so designing for the appropriate components is paramount to achieving good product quality while balancing costs. Here are some well-known wire harness component suppliers: TE Connectivity: One of the largest manufacturers of connectors, sensors, and other components used in wire harnesses. Others in the TE brand family include AMP, Deutsch, and Raychem. Molex: Specializes in electronic connectors and interconnect solutions. They offer a wide variety of connectors and cable assembly solutions used in wire harnesses for consumer electronics, automotive, and industrial applications. Amphenol: A leading manufacturer of connectors, cables, and interconnect systems for various industries, including automotive, aerospace, and telecommunications. Delphi Technologies (Aptiv): Provides electrical and electronic solutions for the automotive industry, including wire harnesses, connectors, and other components. Panduit: Specializes in infrastructure solutions, including cable management, wiring accessories, and connectors for various industries. On the other hand, sourcing substitute alternate components with the same build quality but different manufacturers can achieve substantial cost savings. Here are some well-known wire harness component suppliers from Taiwan: GEM Terminal: Manufactures and sells terminals, plug inserts, housing and electronic connectors for AC and DC power cords with additional locations in China and Vietnam. Hulane: Offers self-developed products such as laser-welding terminals, automotive and electric vehicle connectors, fuse boxes, crimping machines, grommets, and other rubber-related parts. Additional factories in Indonesia, Vietnam, and China K.S. Terminals (KST): Started out as an OEM for electrical terminals and eventually branched out into lighting systems, communication components, automotive connectors, green energy connectors, wiring accessories and application tools. Additional branches in China and a Thailand subsidiary. Song Chuan: World class manufacturer of power electromechanical relays and provides switching solutions for Industrial, Automotive, Appliance, HVAC, Power and Green Energy Applications. As an example, below is a price comparison of different terminal manufacturers regarding the same quick disconnect female flag terminal. KST is able to fulfill the same requirements and specifications with a cost effective solution with a price up to 8 times less than other suppliers. Clearly, choosing substitute alternate components throughout an entire wire harness can add up to huge cost savings. Here at Everlink, we balance high quality engineering and design with cost effective sourcing from Taiwan component suppliers to meet the demands of complex custom wire harness projects and are always accommodating of different requests and requirements.
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A pressure switch and a pressure sensor/transducer are two different devices used to measure and respond to changes in pressure, but they serve distinct purposes and operate in different ways. Here's an overview of the key differences between them:
1. Purpose: Pressure Switch: A pressure switch is primarily used to detect changes in pressure and trigger an electrical or mechanical action when a predefined pressure threshold is reached. It is commonly used in applications where the pressure needs to be monitored to control a system, such as turning a pump on or off when a certain pressure level is reached. Pressure Sensor: A pressure sensor, also known as a pressure transducer or pressure transmitter, is used to continuously measure and convert pressure into an electrical signal (usually voltage or current). It provides a real-time output that can be used for monitoring and control purposes, but it doesn't have built-in switching capabilities. 2. Operation: Pressure Switch: Typically has a mechanical mechanism (mobile arm pin and diaphragm disc or is spring operated) that actuates a switch when the pressure exceeds or falls below a preset level. The switch either opens or closes an electrical circuit, which can then control other devices or processes. Pressure Sensor: It converts the pressure it senses into an electrical signal (e.g., a 4-20 mA current signal or a 0-5 V voltage signal). This is typically achieved using a piezoelectric sensor design. This signal can be sent to a controller, data logger, or display device for continuous monitoring and recording. 3. Output: Pressure Switch: The output of a pressure switch is typically in the form of a discrete binary signal, such as an open or closed circuit. It is used for on/off control. Pressure Sensor: The output of a pressure sensor is an analog signal that provides a continuous and proportional representation of the pressure being measured. This signal can be used for precise measurement and control. 4. Applications: Pressure Switch: Common applications include pump control, pressure relief valve activation, pressure safety interlocks, and other scenarios where discrete control actions are needed based on pressure thresholds. Pressure Sensor: It is used in a wide range of applications, including industrial process control, automotive and aerospace systems, medical equipment, HVAC systems, and anywhere precise and continuous pressure monitoring is required. In summary, a pressure switch is primarily used for on/off control based on pressure thresholds, while a pressure sensor is used to provide continuous and accurate pressure measurements in various applications. The choice between the two depends on the specific requirements of the system or process being monitored or controlled.
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Why Wire Harnesses Vary in Cost9/20/2021 Wire harnesses vary in cost for several reasons, including complexity, materials, labor, customization, and quantity. Here are some key factors that contribute to the variation in cost for wire harnesses:
1. Complexity and Design: The complexity of the wire harness design is a significant factor in determining cost. More complex harnesses with a large number of wires, connectors, and intricate routing may require specialized manufacturing processes, which can drive up costs. 2. Materials Used: The type and quality of materials used in the wire harness also impact cost. High-quality wires, connectors, insulating materials, and protective coverings can increase the overall cost of the harness. 3. Labor Costs: The labor involved in assembling and manufacturing wire harnesses can vary based on factors such as the level of skill required, assembly time, and the complexity of the design. Skilled labor for intricate harnesses may come at a premium. 4. Customization: Customized wire harnesses that are tailored to specific applications or industries may be more expensive than off-the-shelf or standardized harnesses due to the additional design and engineering work involved. 5. Quantity: The volume or quantity of wire harnesses being produced can affect the cost. Typically, larger orders or bulk production result in lower unit costs due to economies of scale. Smaller quantities or one-off custom harnesses tend to be more expensive on a per-unit basis. 6. Connector Complexity: The type and number of connectors used in the harness can influence the cost. Specialized or proprietary connectors can be more expensive than standard connectors. 7. Lead Time: The urgency of the order can also impact the cost. Rush orders or tight deadlines may incur additional expenses for expedited production. 8. Quality Control and Testing: Rigorous quality control and testing procedures can add to the cost, especially for applications where reliability and safety are paramount. 9. Certification and Standards: Wire harnesses used in certain industries, such as automotive or aerospace, may need to meet strict certification and quality standards. Complying with these standards can require additional testing and quality control measures, adding to the cost. 10. Supplier and Location: The choice of supplier and their location can affect costs. Different regions may have varying labor and material costs, which can influence the overall price of the harness. In summary, wire harnesses vary in cost due to a combination of factors related to their complexity, materials, labor, customization, quantity, industry standards, and specific application requirements. When sourcing wire harnesses, it's essential to consider these factors and work with reputable suppliers to ensure that the harness meets your specific needs and budget constraints. Here at Everlink, we balance high quality engineering and design with cost effective sourcing from Taiwan component suppliers to meet the demands of complex custom projects and are always accommodating of different requests and requirements.
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Introduction Air compressors play a vital role in various industries and applications, from inflating tires to powering pneumatic tools. One essential component that ensures the efficient and safe operation of an air compressor is the pressure switch. In this blog, we'll explore the inner workings of a pressure switch in air compressors and understand its crucial role in maintaining the desired air pressure. The Basics of Air Compression Before delving into the pressure switch's functioning, it's essential to grasp the basic principle behind air compression. An air compressor works by drawing in atmospheric air and compressing it to a higher pressure before storing it in a tank. The stored pressurized air can then be used to perform various tasks, such as operating pneumatic tools, filling tires, or powering machinery. The Need for Control: Pressure Regulation In most applications, maintaining a consistent and controlled air pressure is critical for safety, efficiency, and performance. This is where the pressure switch comes into play. Its primary function is to regulate the air compressor's operation by turning it on and off as needed to maintain the desired pressure level in the tank. The Anatomy of a Pressure Switch A pressure switch is a small but vital component of an air compressor. It consists of several key elements: 1. Pressure Sensing Mechanism: The heart of the pressure switch is a diaphragm or piston that senses the air pressure in the tank. When the pressure in the tank falls below a preset lower limit, the sensing mechanism activates. 2. Switch Contacts: The pressure sensing mechanism is connected to a set of electrical contacts. These contacts can either be normally open (NO) or normally closed (NC) depending on the specific design of the switch. 3. Adjustment Mechanism: Pressure switches often have an adjustment mechanism that allows users to set the desired pressure range. This adjustment screw or knob can be turned to increase or decrease the pressure at which the switch activates. How it Works
Here's a step-by-step breakdown of how a pressure switch operates: 1. Initial Setup: When you first install the pressure switch, you adjust it to the desired pressure range. For instance, if you need the compressor to turn on when the tank pressure falls below 90 psi and turn off when it reaches 120 psi, you set these values accordingly. 2. Compressor Starts: As you start using the air compressor, it operates, and the tank pressure begins to drop as air is drawn from it. 3. Pressure Drop Detected: When the tank pressure reaches the lower preset limit (90 psi in our example), the pressure switch's sensing mechanism detects this drop and activates. 4. Switch Actuation: Depending on the design, the switch either closes a normally open (NO) contact or opens a normally closed (NC) contact. This electrical action triggers the compressor motor to turn on. 5. Air Compression: With the compressor motor running, air is compressed and pumped into the tank, raising the pressure inside. 6. Pressure Recovery: As the tank pressure rises and reaches the upper preset limit (120 psi in our example), the pressure switch senses this and deactivates. 7. Switch Deactuation: Again, depending on the design, the switch returns to its normal state, either opening the NO contact or closing the NC contact, which turns off the compressor motor. Conclusion In summary, a pressure switch is a crucial component in an air compressor system that ensures the controlled and efficient operation of the compressor. By monitoring tank pressure and activating the compressor as needed, it helps maintain a stable and safe environment for various applications. Understanding how a pressure switch works is essential for anyone using or maintaining air compressors, as it allows for proper adjustment and troubleshooting when necessary.
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It is definitely not easy for manufacturers, importers, and exporters to navigate through these difficult tariff times. It is a lose-lose situation for all parties as margins become smaller and profits begin to drop. The last thing anybody wants to do is increase retail prices for the American consumer. Almost all Chinese import products will have some sort of tariff applied across all lists totaling $550 Billion: $34B (List 1), $16B (List 2), $200B (List 3), $300B (List 4). Pressure switches are no exception to this and have long been included in List 1 under HTS code 8536.50.90 with the broad heading: Switches nesoi, for switching or making connections to or in electrical circuits, for a voltage not exceeding 1,000 V. Fortunately, there is some reprieve as USTR granted exclusions for specific applications on April 18, 2019 (effectively backdated to July 6, 2018) under HTS code 8536.50.9065 with the heading: Pressure switches designed for use in heat pumps and air-conditioning condensers having a rating of 1.90 megapascals or more but not over 4.55 megapascals. Here at Everlink, we take pride in consistently delivering high quality pressure switches at an affordable price point. We treat our clients as long term partners and are always accommodating of different requests and requirements. |